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All anaerobic digestion systems adhere to the same basic principles whether the feedstock is food waste, animal manure or wastewater sludge. Although the process is the same, designs will vary from digester to digester. Design variations are described below followed by descriptions of digester categories. The main categories of digesters are stand-alone digesters, on-farm digesters, and digesters at wastewater treatment plants.
Digester systems are built for many different reasons and there are many ways to describe them. The most common distinctions include:
Digesters are designed to run at different target temperature ranges. The temperature ranges are typically 86 - 100○ F for mesophillic and 122 - 140○ F for thermophilic. There are different populations of anaerobic microbes that thrive in these temperature zones.
Generally, thermophilic anaerobic digestion (AD) would be used when greater pathogen kill is necessary. This temperature range can produce "Class A Biosolids". Class A Biosolids is a designation for dewatered and heated sewage sludge that meets U.S. EPA guidelines for land application with no restrictions. Thus, Class A Biosolids can be legally used as fertilizer on farms, vegetable gardens, and can be sold to home gardeners as compost or fertilizer. Thermophilic digesters require less time to process feedstocks but may have higher costs and be more difficult to operate.
In general, mesophillic digesters are easier to operate and maintain, but will not result in sufficient pathogen kill to produce Class A Biosolids.
Learn more about biosolids
Some digesters are designed to process one type of feedstock and other digesters are designed to process multiple feedstocks. Co-digestion is often a driver for the development of anaerobic digesters. Many feedstocks require or can benefit from pre-processing before digestion (e.g., blending, screening, thermal conditioning, etc.)
Wet and dry classifications of digesters refer to the moisture content of the feedstocks. Wet digesters are more common that dry. A wet digester or low solids AD system generally processes feedstock with less than 15 percent solids content. The feedstocks for a wet digester are typically in slurry form and can be pumped.
A dry digester or a high solids AD system generally processes feedstock with greater than 15 percent solids content. The feedstocks for a dry digester are often described as stackable.
In a batch digester, feedstocks are loaded into the digester all at once. Following loading there is a set period of time for digestion to occur. Following this time period, the digester is manually emptied and reloaded.
In a continuous flow digester, feedstocks are constantly fed into the digester and digested material is continuously removed.
Most stand-alone digesters accept and process feedstocks from one or more sources for a tipping fee. Stand-alone digesters can be operated as organics recycling businesses, community-based operations or built by a municipality to manage residential food waste.
Other stand-alone digesters are built to process industry specific wastes. This is common in the food and beverage industry. These digesters are co-located at processing plants and are designed to process a certain kind of material. These units typically do not accept other feedstocks from offsite sources.
The primary feedstock processed in stand-alone digesters is food waste. However, digesters built to process food waste can also co-digest other organic materials, such as yard waste, manures and wastewater solids.
Demand for stand-alone digesters is increasing to address the increase of diversion of food waste from landfills.
On-farm digesters can bring great value to farmers
Photo of a dairy farm with anaerobic digestion system tanks in the background and cows in the foreground.and the surrounding community. Digesters can help farmers manage nutrients, reduce odors, and generate additional farm revenue. Dairy, swine and poultry are the primary animal types for farms with digesters. On-farm digesters can also accept outside food waste as a feedstock.
The most common digester system technologies on farms in the United States are: plug flow, complete mix, and covered lagoons.
Learn more about on-farm digesters and how value can be recovered from waste (manure)
The type of digester used on farms is typically determined by the manure management practices in place and type of animal manure that is fed into the digester. Biogas collected from the anaerobic digester systems is often used to generate electricity, to fuel boilers or furnaces, or to provide combined heat and power.
As of January 2019 there are 248 operating digesters on livestock farms in the United States. This data is tracked by EPA’s AgSTAR program.
Learn more about AgSTAR Data and Trends
Plant operators, industry associations, research institutions,
Aerial photo of the two anaerobic digesters at the Central Marin Sanitation Agency treatment plant in San Rafael, CA.and state and federal agencies are now using the term “Water Resource Recovery Facility (WRRF)” to refer to Wastewater Treatment Facilities (also known as Publicly Owned Treatment Works or POTWs). The term “Water Resources Recovery Facility” acknowledges their ability to produce clean water, recover nutrients (such as phosphorus and nitrogen), and reduce our dependence on fossil fuel through the production and use of renewable energy.
The use of anaerobic digestion at WRRFs in the United States dates back to the early 1900’s. Over the last century, there have been both advancements and setbacks in the development of the technology. Anaerobic digestion is both a biological process and an engineered system that requires expertise in both disciplines for success.
The primary purpose of anaerobic digesters at WRRFs is to treat wastewater solids. As a result, these digesters are subject to EPA biosolids regulations (40 CFR Part 503). WRRF digesters vary in a number of ways including:
In the United States, over 1,200 WRRFs have anaerobic digesters that treat wastewater solids and produce biogas. While a number of these WRRFs flare-off the biogas produced in this process, more than half use the biogas they produce as an energy resource for producing electricity or usable heat. Of the facilities using their biogas for energy, about one third are generating electricity that is used for operations at the facility. Of the WRRFs generating electricity from biogas, almost 10 percent sell this electricity to the grid. About 2 percent of the WRRFs with digesters process the biogas into a form that is pure enough to inject into natural gas pipelines.
These uses of biogas generated at WRRFs are documented in a database maintained by the Water Environment Federation (WEF).
Access to WEF Database
Sludge treatment facilities have been using the process of anaerobic digestion for over a century to treat, reduce, and make use of sewage sludge. Below is a primer on anaerobic digestion and its products and benefits, an overview of the process and types of digesters, as well as an introduction to its relevance in the wastewater and sludge industry.
Anaerobic Digestion (AD) is a set of biochemical steps where microorganisms break down organic matter such as sewage sludge, manure, and food waste in the absence of oxygen (hence the word “anaerobic”), primarily producing gases such as methane and carbon dioxide, as well as the organic wet mixture or residue called digestate. Anaerobic digestion is used to treat or stabilise food and other organic wastes, reduce greenhouse gas emissions of otherwise landfilled waste, and extract renewable energy in the form of biogas.
The anaerobic digestion process is utilised by a range of industries, including the agriculture industry for processing manure, energy crops, and agro-industrial waste; the food and manufacturing industries for food processing waste, slaughterhouse waste, pulp and paper liquors, and biochemical waste; and the waste and wastewater industries for municipal organic waste and sewage sludge treatment or management.
It is important to note that there are other stabilisation processes for sludge besides anaerobic digestion, such as alkaline stabilisation (typically the addition of lime), aerobic digestion, composting, and autothermal thermophilic digestion. Anaerobic digestion is, however, seen to be one of the most sustainable options in that it produces renewable energy and lessens sludge or organics volume.
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The two main by-products of the anaerobic digestion of organic waste can be used in a variety of ways:
Biogas
Biogas is mostly methane and carbon dioxide with small amounts of other gases and water vapor. It can be refined or purified to just biomethane to increase its commercial value. Biogas is considered as a renewable energy source and can be used as fuel or to produce heat and/or electricity. For the sewage industry, the biogas produced from sludge can be used to help offset the energy costs of a wastewater treatment .
Digestate
In the wastewater or sewage industry, digestate or digested sludge is often referred to as “biosolids,” and its management represents a large percentage of a wastewater treatment plant’s operational expenditures, often at about 40%.
An anaerobic digester is the main component of an anaerobic digestion system (also called biogas systems), it is a construction where the anaerobic digestion takes place. These systems can be made using various configurations and different types of equipment, based on the type of feedstock to be treated, the space available, and the final products desired.
There are various types of anaerobic digesters used across industries and can be classified based mainly on two things: the engineering design of the reactor and the design of the digester tank or vessel.
There are various types of anaerobic digesters used across industries and can be classified based mainly on two things: the engineering design of the reactor and the design of the digester tank or vessel.
Digester classifications based on reactor engineering:
Digesters such as the complete mixed digester, plug flow digester, and the mixed plug flow digester, are often used in farms.
Digester classifications based on digester tank or vessel design
In the sewage sludge industry specifically, digester tank designs tend today to be cylindrical, with egg-shaped digesters becoming more popular in Europe and lately in the United States.
Digesters can also be classified by whether they treat a low versus high proportion of solids, or whether they operate in mesophilic or thermophilic temperature conditions. The mesophilic temperature range of 30 to 38°C is most commonly used and caters to “mesophilic” bacteria which thrive in such conditions, while “thermophilic” bacteria prefer the temperature range of 50-57°C.
A cylindrical anaerobic digester at a co-digestion plant in Norway
It is important to note that each type of digester has its own pros and cons, and that the nature and quantity of the material to be digested, as well as the supporting infrastructure, are essential in choosing the digester best suited for a facility. Some digesters need hardly any monitoring, such as lagoons and dome digesters. Others will need more sophisticated monitoring equipment, such as temperature transmittors and more high-tech monitors such as those for volatile fatty acids (VFA), online dry solids (DS), and alkalinity.
There are four main steps that take place during the anaerobic digestion process, these are hydrolysis, acidogenesis, acetogenesis, and methanogenesis, all carried out by a diverse microbial community in the absence of oxygen. Though these are the main biochemical reactions that happen within a digester, it must be noted that there are other biochemical reactions occurring in the digester not discussed below.
Hydrolysis is often referred to as the rate-determining step of anaerobic digestion, meaning it is the slowest step and plays a big part in determining the length of time that the feedstock will stay in a digester. This is why pretreatment methods for anaerobic digestion, such as thermal treatment, focus on optimising this step (see advanced anaerobic digestion section below).
The steps acidogenesis and acetogenesis happen next simultaneously.
Feedstocks high in protein, such as sewage sludge, also produce plenty of ammonia from the breakdown of amino acids, which is known to make anaerobic digestion more difficult. Besides ammonia, carbon dioxide and other gases such as hydrogen sulfide may be produced.
Step 3: Acetogenesis - Acetate is formed from the short-chain/volatile fatty acids in acidogenesis, along with hydrogen and carbon dioxide.
Wastewater treatment plants that treat sewage sludge can use anaerobic digestion as a stabilisation or treatment method for sludge. A stabilisation process primarily reduces odour and the decay of sludge while lowering the number of harmful microorganisms. Anaerobic digestion, in addition, lessens the volume of biosolids and gains biogas for the plant. Reduction of final sludge or biosolids occurs because in the sludge are turned into biogas.
Sludge is introduced to the anaerobic digestion system after primary and secondary wastewater treatment (or the activated sludge process) and thickening. Once anaerobically digested, the sludge (at times referred to as biosolids or digestate by this point) is usually dewatered before the final handling method.
Anaerobic digestion has multiple benefits. It helps many wastewater utilities or municipalities to achieve the following, but with several limitations.
Not all anaerobic digestion systems, however, especially when used without additional treatment methods, can reduce pathogens sufficiently so that the harmful bacteria do not regrow in the final biosolids product.
Nonetheless, biogas extraction in today’s anaerobic digestion systems is highly inefficient. Plenty of energy can remain trapped in the final product when the breakdown of the organic material in the digester is not optimised. This means that methane and carbon dioxide that could otherwise be captured during the process can escape the biosolids material later on when there is further degradation. If this happens in open air (such as a landfill), or in an incineration facility, then the emissions add to the climate problem. The biosolids product also retains sufficiently foul odour to make handling the material unpleasant.
Anaerobic digestion lessens final biosolids volumes, affecting the costs of transport/further handling.
Unfortunately though, most anaerobic digestion systems without additional treatment still produce copious volumes of biosolids because plenty of water is trapped within the material even after final dewatering. Learn about sludge dewatering here.
Wastewater treatment facilities worldwide with enough digestion capacity also use anaerobic digestion to digest a combination of sewage sludge and other organics. This is called “co-digestion”. Sewage sludge can be co-digested with fats, oil, and grease (FOG) – a common high-strength liquid organic waste produced by the food processing industry, and with other organic solid wastes such as household or industry food . Co-digestion offers the extra advantage of using food or organic waste as an energy resource without needing to build extensive infrastructure to handle a separate waste stream.
Advanced Anaerobic Digestion (AAD) is a term used to describe the anaerobic digestion when it is modified to create higher quality biosolids (often referred to as Class A by US Environmental Protection Agency standards) and more biogas through higher volatile solids reduction. Modifications that achieve AAD include thermophilic anaerobic digestion, staged thermophilic anaerobic digestion, staged mesophilic anaerobic digestion, acid/gas phased anaerobic digestion, and temperature-phased anaerobic digestion ().
There are also pretreatments that achieve advanced anaerobic digestion. They are classified as either thermal, physical, chemical, or electric pretreatments. Among these, thermal hydrolysis as pretreatment for mesophilic anaerobic digestion stands out due to its growing use in plants around the globe.
Remember that hydrolysis is actually the first step of the actual anaerobic digestion process. By optimising and expediting this step in a pretreatment system, the benefits of anaerobic digestion are boosted, with additional advantages. Thermal hydrolysis, for example, provides up to 50% more biogas, up to 50% more biosolids reduction, and increased digestion capacity, compared to conventional digestion, among other benefits. It is a method used in over 130 plants to date and is already used to pretreat over 50% of the United Kingdom’s wastewater sludge before anaerobic digestion. Learn more about thermal hydrolysis here
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